GB2543802A

GB2543802A - Composite panel unit

Info

Publication number: GB2543802A
Application number: GB1519093.7A
Authority: GB
Inventors: Back Haslen
Original assignee: Individual
Current assignee: Individual
Priority date: 2015-10-28
Filing date: 2015-10-28
Publication date: 2017-05-03
Also published as: GB201519093D0

Abstract

A water vessel comprises at least four panel units, with each panel unit having three or more sides, and having at least one joining part 48 on a portion of each side, wherein each joining part 48 is adapted to join the panel unit to a joining part 46 on another panel. The panel unit is provided with inner 34 and outer 32 composite panels separated by a profile units 38, 40. The core 36 of the inner and outer composite panels may be filled with solid or other foams. The inner panel may be constructed from fire resistant fibres and phenolic resins, while the outer panel may be frmed from epoxy based resin materials. The hull formed by the panels may be chined, and have at least one strengthening stringer (27, 28, 30, 31, fig 4). The lower hull panels are slotted into the keel strake (14, fig 4). A method of constructing a water vessel from composite panels is disclosed, as are panel units for constructing buildings or bridges.

Description

Composite panel unit

FIELD OF THE INVENTION

The present invention relates to a composite panel unit, for the construction of doors, windows, and buildings such as houses, warehouses, hospitals, bridges, sky scrapers, and other structures, and to the construction of water vessels, more particularly ships, yachts, boats and tenders, and vehicles, more particularly amphibious vehicles using the composite panel. More particularly, the present invention relates to a composite panel unit, comprising parallel inner and outer composite panels, an intermediate cavity or void between the two panels, and one or more profiles for connection of the panel unit to one or more other panel units, and the use thereof for the construction of buildings and methods of manufacturing doors, windows, and buildings, bridges, and for the construction of water vessels and methods of manufacturing vehicles, amphibious vehicles and water vessels.

BACKGROUND OF THE INVENTION

Composite panels for use in the construction of buildings and other structures should be constructed using methods that provide a light, strong structure, cost effective to engineer and produce, and materials with proven civil engineering history with a long service life. It is also desirable, especially for buildings used as accommodation and other civil uses that the materials used enable acoustic insulation to be good. A low embedded energy content and fire resistance are also important properties of the structure of such composite panels. U.S. patent application, US20100050549, discloses a composite panel unit comprising an inner and an outer composite panel. The cavity or void between the inner and outer panels in this building system is filled by a layer of adhesive and a reinforcement member such that no cavity or void remained between the two panels post construction. U.S. patent, US5,168,674 to Mol then teaches a prefabricated modular twin wall panel unit for construction of buildings, the panel possess a cavity or void that can form a vacuum between the inner and outer panels post construction once attached to a vacuum pump. However this system requires the use of dowel separators to maintain the cavity space between the inner and outer panels which adds to the cost and complicates the mode of manufacture.

Water vessels, for example ships or boats, and vehicles including amphibious vehicles should be constructed using methods that provide a light, strong structure, cost effective to engineer and produce, and materials with proven maritime service history with a long service life. It is also desirable, especially for high value water vessels such as ships, yachts, super yachts and their tenders, that the materials used enable acoustic and thermal insulation to be good. Fire resistance is also an important property of the internal and certain external areas of the structure of water vessels. US-A-2010/101478 discloses a prefabricated panel assembly for use in constructing a marine vessel comprises a plurality of elongated, roll-formed metal panels fixed side to side by longitudinal weld seams. CH 675103 discloses a boat hull produced using a sandwich construction method. A layer of fibre-reinforced polyester or epoxy resin is applied to the bulkheads and ribs, followed by a layer of closed-cell foamed resin. US-B-5,372,763 discloses a method of making a boat by forming an outer hull by applying successive layers of a coating, resin and fibres to a female mould and allowing to cure and forming an inner composite structure, attaching the inner and outer walls and injecting a syntactic foam between the inner and outer walls.

Other types of panels and panel units have also be used in the past to form water vessels.

Unfortunately, water vessels constructed using known methods do not provide all the necessary advantages.

Description of the Invention

Unfortunately, building structures constructed using such known methods do not provide all the necessary advantages, and certainly not in a cost effective manner, comprising; structural and environmental integrity, energy capture, active thermoregulation and fire protection.

It is an aim of the first aspect of the present invention to address this issue.

The present invention accordingly provides, in a first aspect, a panel unit having three or more sides, and having at least one joining part on the peripheral portion of each side, wherein each joining part is adapted to join the panel unit to a joining part on another panel unit.

This is greatly advantageous because constructing a building, or other structure, using panel units enables the use of prefabricated units with consequent benefit in speed of construction. Thus, preferably, the panel units are prefabricated.

The material used within the composite structures enable structures to be used with both a minimum life cycle embedded energy cost and the structures produced from the panels to have the lowest possible operating energy cost.

Most importantly the exterior of a building should be efficient at energy harvesting, and combined with a heat pump so that a significant amount of the energy falling on the building in the form of solar radiation, can be efficiently be stored in vacuum tanks for further use in heating and / or cooling the building . The present invention enables the surface of the building to provide the thermal energy requirements for the building or a significant % thereof depending on buildings size, use, and location.

Generally, each panel unit on each of its sides may be joined to at least one other panel unit. This is advantageous because it provides a modular construction system for constructing buildings and other structures.

In addition, or as an alternative to mechanical joining parts, the joining part may be chemically or thermally joined by e.g. adhesives, welding or brazing. It is often beneficial to strengthen joining parts using such adhesive or welding methods in addition to the mechanical joining parts.

The panel units of the present invention preferably comprise at least one composite panel to provide strength, lightness and insulation.

This may be advantageously achieved if a plurality, or each, panel unit comprises an outer composite panel and an inner composite panel. The outer composite panel and the inner composite panel may be made of the same material. However, preferably, the outer composite panel and the inner composite panel are made of different materials.

In particular, it is advantageous if the outer composite panel is designed as a structural panel and the inner panel is designed as a fire resistant panel. Thus, the building or structure constmcted of such panel units would have a double layered structure with the outer layer designed for structural strength and the inner layer designed for both strength and fire resistance. It is a preferred embodiment that the cavity or void between the inner and outer panels is partly or fully preserved after construction, optionally with a system built into the building or structure that enables a vacuum to be created in this cavity or void between the inner and outer panels.

The cavity or void between the inner and outer panel of the panel unit of the present invention is not filled with adhesive, or other material, during construction and therefore the cavity or void forms a continuous or localized area within one or more sides of the building or structure. It is contemplated that this cavity or void may be connected to an in-house vacuum pump to provide thermal regulation of the internal environment of the building, for example wherein the occupant of the building or structure controls an on/off setting for the pump to determine whether air present in the void is evacuated by the pump.

In another embodiment, it is contemplated that the air pressure in the space may be actively controlled either by a human operator or an electronic or mechanical device to either maximize or minimize the thermal energy transfer between the outer and inner panels.

To provide both strength and a means of providing joining parts, it is preferred that the panel units are arranged such that the outer composite panel and the inner composite panel are connected by at least one profile extending along and fixed to a portion of the periphery of an edge of each of the inner panel and outer panel. Preferably, a plurality, or each, profile comprises a joining part.

Preferably, the building or structure may also comprise one or more girders and columns extending generally within the building to provide additional strength.

In a preferred embodiment, the inner or outer panel may comprise: a) a first layer of a first fibre reinforced resin, b) a core layer of an aggregate, and c) a second layer of a second fibre reinforced resin.

Preferably, the first and/or the second fibre reinforced resins are independently selected from fibre reinforced thermosetting resins.

It is preferred that the thermosetting resins are independently selected from epoxy resins, polyurethane resins, vinyl ester resins, polyester resins and phenolic resins.

It is also preferred if the first and/or the second fibre reinforced resins independently comprise fibres of; glass, carbon, aramid, basalt and/or a vegetable fibre.

In the building composite structure the preferred materials for the composite cores are quarried or recycled grits and the skins of the composites are made from basalt fibre, bonded with organic resins. The resulting structures require less than 90% of the energy to build and recycle then current reinforced concrete or brick/ block construction.

The core layer aggregate comprises a grit, preferably grit, preferably with a diameter between about 3 and 7mm in diameter, or a hollow glass microsphere with a diameter less then 1mm. The aggregate may further comprise a cementitious material and or an organic resin in about less than 10% w/w, preferably about 3-5% w/w ratio to the grit or greater then 30% for the hollow glass microspheres. It is understood the w/w amount of a cement and or resin will be suffice to coat the grit particle surface area after blending or mixing together of the constituents of the aggregate.

For excellent structural properties, it is preferred if the outer panel of the panel unit comprises an outer panel first layer of a first fibre reinforced epoxy resin, an outer panel core layer of an aggregated comprising a grit mixed with a cement or resin, and an outer panel second layer of a second fibre reinforced organic resin. Preferably, the fibre of the first fibre reinforced epoxy resin and/or the second fibre reinforced epoxy resin comprises glass fibre.

It is further contemplated that the core layer can be varied according to the structural requirements of the building or the specific location of the panel unit within the building. For example in the construction of tall buildings or structures, such as sky scrapers the use of lightweight cores, such as hollow glass microspheres, is preferable because of their light weight. The use of hollow glass microspheres, or equivalent other material, is also used for panels to create opaque or transparent panels which is applicable to any aspect of the invention described herein. For panel units surrounding or situated in proximity to structural elements such as girders, beams, columns the voids between either the grit or microspheres are filled with a bonding agent to maximize strength of these structural components

For good strength and fire resistant properties, preferably the inner panel of the panel unit comprises an inner panel first layer of a first fibre reinforced fire retardant resin, an inner panel core layer of an aggregate, and an inner panel second layer of a second fibre reinforced fire retardant resin. Preferably, the fibre of the first fibre reinforced fire retardant resin and/or the second fibre reinforced fire retardant resin comprises fibres of an inorganic material and more preferably basalt or glass fibre. The resin of the first fibre reinforced fire retardant resin, the inner panel core layer and the second fibre reinforced fire retardant resin may be independently selected (i.e. may be the same or different) from resin containing a fire retardant additive and/or a phenolic resin.

It is advantageous in certain circumstances to have a hollow core in the structural elements to route building infrastructural services such as air, electricity, fire protection, water and computer networking systems. Another embodiment of the panel consistent with the present invention further comprises a series of tubes that comprise a flexible material such as silicon, rubber, PU, etc and a stiff material to minimize heat and noise transmission through the thermal and acoustic bridge positioned between the inner and outer panels thereby spacing the panels to prevent them from collapsing inwards when a vacuum is applied. Thus, the present invention according provides, in a second aspect, a method of manufacturing a building or structure using the panel unit, the method comprising, forming at least one composite panel by laminating together: a) a first layer of a first fibre reinforced resin, b) a core layer of an aggregate, aggregate-cement or aggregate-resin mix, c) a second layer of a second fibre reinforced resin, d) aligning an inner panel and an outer panel in parallel to form a void between the panels, e) connecting panel units by at least one profile extending along and fixed to a portion of the periphery of an edge of each of the inner panel and outer panel whereby the cavity or void between the inner and outer panels is retained and f) repeating step e) until desired configuration of panel units has been achieved for construction of the building or structure.

In another embodiment, it is contemplated that the core between the laminates or skins of the composite panel is filled with a foam porous in one direction. It is understood that an vacuum air pump when connect to the panel unit warm air trapped in the foam is transferred to a heat pump and / or thermal storage medium to provide a thermal energy source for managing the internal temperature of the building / structure.

In another embodiment, it is contemplated that the outer surface may comprise photovoltaic panels to maximize the energy capture of the building, providing both an electrical and enhanced thermal capture capability.

In another embodiment, it is contemplated that the outer panels may be formed to a shape that conforms with building norms or standards, to enable a composite structure to fit into a conventional built environment.

In another embodiment, it is contemplated that the void between the grit in the inner and outer laminates or skins of a panels comprise a foam porous in one direction. It is understood that a liquid (eg. water) storage tank when connect to the void directs water into the void to either increase its specific heat capacity, to regulate its temperature, and in the event of a fire, to maximize the time it takes to raise the structural materials beyond their operating temperatures.

In another embodiment, it is contemplated that the cavity or void between the inner and outer panels is used to provide for protected routing / transporting of building infrastructural services, such as water, data, air, electricity, etc.

In another embodiment the internal surfaces of the inner and outer panels are coated in a reflective material with a greater then 95% reluctance, to minimize radiant energy transfer across the space separating the panels.

In a preferred embodiment of the panel, laminating may comprise a wet lay-up, a VARTM, a pre-preg or pultrusion process comprising layering a composite precursor comprising: a) a first resin impregnated reinforced fibre material, b) a core layer of the aggregate, aggregate-cementitious material or aggregate-organic resin mix, or hollow glass microspheres with either a cementitious material or organic resin mix and c) a second resin impregnated reinforced fibre material; and pulling the composite precursor through a curing die.

It is contemplated that the method disclosed herein the first aspect of the invention for construction of buildings and structures, can be applied in the same manner, or with amended core and layer materials to the construction of bridges. For the bridging the optimum combination of strength and stiffness in the structures enables them to be produced from the minimum quantity of materials, ensuring they have the lowest lifecycle energy requirement.

Many of the optional and preferred features of the second aspect of the invention correspond to those of the first aspect and third aspect with appropriate modification.

Thus, the present invention according provides, in a third aspect, a method for the construction of water vessels, vehicles and amphibious vehicles, and methods of manufacturing water vessels, vehicles and amphibious vehicles

The third aspect of the present invention accordingly provides a water vessel comprising at least four panel units, each panel unit having three or more sides, and having at least one joining part on the peripheral portion of each side, wherein each joining part is adapted to join the panel unit to a joining part on another panel unit. A particularly advantageous feature of the panel unit of the present invention is the retaining of the cavity or void between the inner and outer panels. In this third aspect of the invention, the cavity or void may be partially or fully retained throughout one or more panel units of the water vessel. Further, this cavity or void may be pressurized by means of an input material such as a gas, preferably air, to maintain stiffness of the inner and outer panels of the panel unit. This in turn provides additional strength and resilience of the water vessel to external forces such as water currents, waves or wind.

Constructing a water vessel using panel units enables the use of prefabricated units with consequent benefit in speed of construction. Thus, preferably, the panel units are prefabricated.

Generally, each panel unit on each of its sides may be joined to at least one other panel unit. This is advantageous because it provides a modular construction system for constructing water vessels. A water vessel according to the first aspect will usually comprise at least one port side hull panel unit, at least one starboard side hull panel unit, at least one deck panel unit and at least one lower hull panel unit. Preferably, the vessel will comprise at least two lower hull panel units. The at least two lower hull panel units may form a chined hull over at least a portion of the length of the water vessel.

It is advantageous if at least some of the panel units form lateral stakes to provide enhanced strength and stiffness to the vessel. The optimum combination of strength and stiffness in the structures of the vessels, vehicles or amphibious vessel, ensure that they sure as light as possible, so they are as energy efficient as possible to operate, which significantly reduces the energy required to operate them.

Preferably, the vessel will further comprise at least one bulkhead panel unit to provide enhanced safety and further structural integrity. Furthermore, the vessel preferably further comprises at least one strengthening stringer. At least one of the strengthening stringers may be a keel stake. Preferably, however the vessel will further comprising at least two lateral strengthening stringers.

One of the great benefits of the invention is that all the hull components of a vessel may be made using panel units. Thus, usually the water vessel will comprise at least six panel units. Normally, each panel unit may have four or more sides.

The, or each, joining part of the panel units will usually comprise a mechanical joining part. The, or each, mechanical joining part may comprises at least one male joining portion, at least one female joining portion or at least one male joining portion and at least one female joining portion.

The panel units of the water vessel preferably comprise at least one composite panel to provide strength, lightness and insulation. The panel units may therefore be monolithic and may form a single hulled structure when joined to construct the vessel.

As an alternative, it may be preferred for reasons of safety and structural integrity that the water vessel is double-hulled. This may be advantageously achieved if a plurality, or each, panel unit comprises an outer composite panel and an inner composite panel. The outer composite panel and the inner composite panel may be made of the same material. However, preferably, the outer composite panel and the inner composite panel are made of different materials.

In particular, it is advantageous if the outer composite panel is designed as a structural panel and the inner panel is designed as a fire resistant panel. Thus, the water vessel constructed of such panel units would have a double hulled structure with the outer hull designed for structural strength and the inner hull designed for both strength and fire resistance.

Preferably, the vessel may comprise at least one fender strake to provide protection when docking and also, especially in larger vessels, to save space inside the hull by acting as a walkway. The fender strakes may be longitudinal strakes joined to a profile.

Preferably, the vessel may also comprise one or more girders extending generally across the beam of the vessel to strengthen the vessel.

In a preferred embodiment, the composite panels may comprise: a) a first layer of a first fibre reinforced resin, b) a core layer of a solid foam, and c) a second layer of a second fibre reinforced resin.

It is also preferred if the first and/or the second fibre reinforced resins independently comprise fibres of glass, carbon, aramid, and/or basalt.

Usually, the solid foam comprises a core resin. The solid foam may comprise an open cell foam, a closed cell foam and/or a syntactic foam. Preferably, the solid foam comprises a syntactic foam, which more preferably comprises a core resin containing hollow particles. The preferred hollow particles are hollow glass particles.

The core resin may be independently selected from epoxy resins, polyurethane resins, vinyl ester resins, polyester resins or phenolic resins depending upon the required characteristics of the core resin.

The stringers, strakes and girders made up from the profiles in the water vessel may be reinforced with a high strength and or modulus fibre such as carbon or aramid or resin containing nano particles comprising multi walled carbon nanotubes, graphene layers or aluminum oxide to provide increased global structural rigidity / stiffness and or strength. In buildings this would apply to the columns and beams.

For excellent structural properties, it is preferred if the outer panel of the panel unit comprises an outer panel first layer of a first fibre reinforced epoxy resin, an outer panel core layer of a syntactic foam comprising an epoxy resin, and an outer panel second layer of a second fibre reinforced epoxy resin. Preferably, the fibre of the first fibre reinforced epoxy resin and/or the second fibre reinforced epoxy resin comprises glass, carbon or aramid fibre.

For good strength and fire resistant properties, preferably the inner panel of the panel unit comprises an inner panel first layer of a first fibre reinforced fire retardant resin, an inner panel core layer of a syntactic foam comprising a fire retardant resin, and an inner panel second layer of a second fibre reinforced fire retardant resin. Preferably, the fibre of the first fibre reinforced fire retardant resin and/or the second fibre reinforced fire retardant resin comprises fibres of an inorganic material and more preferably a basalt, carbon, glass or aramid fibre. The resin of the first fibre reinforced fire retardant resin, the inner panel core layer and the second fibre reinforced fire retardant resin may be independently selected (i.e. may be the same or different) from resin containing a fire retardant additive and/or a phenolic resin.

Water vessels according to the present invention may be constructed efficiently and relatively rapidly. A further advantage of the present invention is that the vessel may be constructed of panel units having two composite panels.

Thus, the present invention according provides, in a third aspect, a method of manufacturing a water vessel, the method comprising, forming at least one composite panel by laminating together: a) a first layer of a first fibre reinforced resin, b) a core layer of a solid foam, preferably a syntactic foam and c) a second layer of a second fibre reinforced resin.

In a preferred embodiment, laminating may comprise a wet lay-up, a VARTM, a pre-preg or pultrusion process comprising layering a composite precursor comprising: a) a first resin impregnated reinforced fibre material, b) a core layer of the solid foam, preferably the syntactic foam, and c) a second resin impregnated reinforced fibre material; and pulling the composite precursor through a curing die.

Many of the optional and preferred features of the thirds aspect of the invention correspond to those of the first and second aspects with appropriate modification. It is contemplated that the method disclosed herein, in the third aspect of the invention, for construction of a water vessel and also be applied to other transportation means such as vehicles such as motorised vehicles, and amphibious vehicles.

The above and other characteristics, features and advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention. This description is given for the sake of example only, without limiting the scope of the invention.

Reference throughout this specification to “an embodiment” or “an aspect” means that a particular feature, structure or characteristic described in connection with the embodiment or aspect is included in at least one embodiment or aspect of the present invention. Thus, appearances of the phrases “in one embodiment”, “in an embodiment”, or “in an aspect” in various places throughout this specification are not necessarily all referring to the same embodiment or aspect, but may refer to different embodiments or aspects. Furthermore, the particular features, structures or characteristics of any embodiment or aspect of the invention may be combined in any suitable manner, as would be apparent to one of ordinary skill in the art from this disclosure, in one or more embodiments or aspects.

Similarly, it should be appreciated that in the description various features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Moreover, the description of any individual drawing or aspect should not necessarily be considered to be an embodiment of the invention. Rather, as the following claims reflect, inventive aspects lie in fewer than all features of a single foregoing disclosed embodiment. Thus, the claims following the detailed description are hereby expressly incorporated into this detailed description, with each claim standing on its own as a separate embodiment of this invention.

DETAILED DESCRIPTION OF THE DRAWINGS

In the description provided herein, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practised without these specific details. In other instances, well-known methods, structures and techniques have not been shown in detail in order not to obscure an understanding of this description.

The present invention is illustrated by the accompanying drawing, in which:

Figure 1 illustrates, in perspective view, a boat according to the third embodiment of the invention.

Figure 2 illustrates a starboard side view the boat of Figure 1.

Figure 3 illustrates a bottom view of the boat of Figure 1.

Figure 4 illustrates a port side, cross sectional view of the boat of Figure 1.

Figure 5 illustrates a cross-sectional view along line A - A of Figure 4.

Figure 6 is a magnified portion of the lower part of Figure 5.

Figure 7 illustrates a cross-section through a panel unit of the present invention.

Figure 8 illustrates the cross sections of profiles used in the panel units of the present invention and in the boat of Figures 1 to 7.

Figure 9 illustrates, in perspective view, a boat according to a third embodiment of the invention.

Figure 10 illustrates a starboard side view of the boat of Figure 9.

Figure 11 illustrates a front view of the boat of Figures 9 and 10.

Figure 1 shows a perspective view of a boat 1 according to an embodiment of the present invention. Figure 2 shows a starboard side view of the boat 1. The boat 1 is a motor boat suitable for use in rivers, estuaries, inshore or offshore. One potential use of the boat 1 is as a tender for a large yacht.

As shown in Figure 1, the boat 1 has a bow 2, a stem 4 and port side panel 6. The port side panel 6 is a panel unit of two composite panels (not shown in Figure 1, see Figures 5 to 7) and acts as a port strake extending substantially the whole length of the port side of the boat 1. The boat 1 has a top deck 8 which also comprises a panel unit of two composite panels (not shown in Figure 1, see Figures 5 to 7). The boat 1 has a cockpit 10 with seats, controls and facilities for the crew and passengers. A fender strake 11 extends from the stem 4 to near the bow 2 of the port side. A similar fender strake (not shown) extends along the starboard side.

As shown in Figure 2, the boat 1 has a keel 12. The boat 1 may have propellers (not shown) that may be inboard or outboard and may be moveable between a working position in the water or out of the water.

Figure 3 shows a bottom view of the boat 1. The lower hull of the boat has port lower hull panel 16 and starboard lower hull panel 18 and keel strake 14 along the keel 12. Both port lower hull panel 16 and starboard lower hull panel 18 also each comprise a panel unit of two composite panels (not shown in Figure 1, see Figures 5 to 7). The two composite panels of the port lower hull panel 16 and starboard lower hull panel 18 form a double-hulled structure.

Figure 4 illustrates a partial vertical section port side view of the boat 1, showing the construction of the boat 1. The cockpit 10 contains a wheel 22. Aft of the cockpit 10, the inboard marine engine 20 is situated toward the stem 4 of the boat 1. The engine 20 drives the propeller(s) (as discussed above, the propeller(s) are not shown). Extending between the bow 2 and stern of the boat 1, are a port waterline stringer 28, a port lower first stringer 30 and, slightly below, a port lower second stringer 31. Together with the keel strake 14, the stringers 28, 30, 31 provide strength and stiffness along the length of the boat 1 at the waterline and below.

Just below the top deck 8, a port gunwale stringer 27 extends from the bow 2 to the cockpit 10 and provides strengthening to the boat 1 forward of the cockpit 10. To provide further strengthening, especially across the beam, a frame 26 is situated half-way between the bow 2 and cockpit 10._Two bulkhead panels 24 formed of panel units comprising two composite panels are situated between the cockpit 10 and bow 2.

The stringers 27, 28, 30, 31 shown in Figure 4 are formed of profiles which extend between the two composite panels which make up a number of the panel units from which the boat 1 is constructed.

Figure 5 is a cross-sectional view (in parallel projection) along line A - A of Figure 4 and illustrates the construction of the boat 1. Figure 6 is a magnified view of the lower part of Figure 5.

As seen in Figure 5, the boat 1 is a box-like structure constructed of top deck panel 8, port side panel 6, starboard panel 7, port lower hull panel 16 and starboard lower hull panel 18. The outer panels 8, 6, 7, 16, 18 are joined at the peripheral portions of their edges by profiles having joining parts as will be explained. A lower deck panel 9 and centre bulkhead panel 56 provide strengthening to the box-like structure formed by the outer panels 8, 6, 7, 16, 18. Additional horizontal decks, bulkheads, and other structures may be added if there is need and sufficient space in a vessel.

The port side panel 6 comprises two composite panels, an outer composite panel 32 spaced from an inner composite panel 34 by an upper profile 38 and lower profile 40. The port panel unit space 36 between the port panel unit outer composite panel 32 and port panel unit inner composite panel 34 may be an air space, may be in vacuum or may be filled with an acoustic and/or thermal insulator material to provide acoustic and/or thermal insulation. The other panels are of generally similar construction forming panel units comprising two composite panels spaced from each other by profiles at the peripheral portions of the edges of the panels.

The profiles have a number of advantages: they space the composite panels of each panel unit, they provide strengthening of the panel units and therefore the boat 1 as a whole and they act as joining parts to join the panel units along their respective edges.

Thus, referring to Figures 5, 6 and Figure 8 (which for clarity shows cross-sections of the profiles alone), the top deck panel 8 is joined at its port edge to the port side panel 6 by means of upper deck panel unit port profile 60 which has a terminal part with a male joining part generally perpendicular to the plane of the top deck panel 8 and adapted to fit the female joining part of the port panel unit upper profile 38. Similarly, the port panel unit lower profile 40 of the port side panel 6 has a terminal male joining part adapted to fit the upper female joining part of the lower deck panel unit port profile 46 which also has a lower female joining part adapted to fit the male joining part of the lower port hull panel unit upper profile 48.

In the lower part of the hull on the port side (as more clearly seen in Figure 6), the male joining part of lower port hull panel unit lower profile 49 fits the female joining part of port lower hull panel port profile 51 so that the port lower hull panel 16 is fixed at an angle, thus forming (with fixings to keel strake 14) a chined hull, reinforced on the port side with port chine profile 58.

At the keel strake 14, the port lower hull panel starboard profile 50 is firmly slotted into a shaped slot in the keel strake 14. Similarly, on the starboard side, starboard side lower hull panel port profile 52 is firmly slotted into a shaped slot in keel strake 14. The keel strake 14 is further reinforced by centre profile 54 and centre bulkhead panel 56 fitted to lower deck panel 9 using centre bulkhead brackets 55.

Generally similar fixings and joining parts are used in the remainder of the boat 1. Thus, a boat according to the invention is strong and light and its construction makes use of prefabricated components firmly and straightforwardly fitted together to enable safe and rapid constmction of even relatively large water vessels.

The profiles used in the fixing of panel units together also provide the structure of the stringers. Thus, on the port side (and referring also to Figure 4), port second lower stringer 31 is formed by the port lower hull panel starboard profile 50. The port first lower stringer 30 is formed by the joined lower port hull panel unit lower profile 49 and port lower hull panel port profile 51. The port waterline stringer 28 is formed by the joined port panel unit lower profile 40, lower deck panel unit port profile 46 and lower port hull panel unit upper profile 48. The port gunwale stringer 27 is formed by the joined port panel unit upper profile 38 and upper deck panel unit port profile 60. The stringers on the starboard side are formed in a generally similar fashion.

Figure 7 illustrates in more detail the structure of a panel unit of the present invention which are used for the structural panels in the boat 1. Thus, port side panel 6 is formed of outer composite panel 32 spaced from inner composite panel 34 by upper profile 38 and lower profile 40. In the boat embodiment, the space 36 between the outer composite panel 32 and inner composite panel 34 is in vacuum to provide excellent thermal and acoustic insulation or is pressurised to increase the stiffness of the structure. In the building embodiment, the space 36 between the outer composite panel 32 and inner composite panel 34 is in vacuum

Spacers (not shown) may be situated in the space 36 to provide increased reinforcement to the panel unit. Alternatively, the space 36 may be filled with air or a thermal and/or acoustic insulation material.

In the boat embodiment, the outer composite panel 32 is formed of three layers: an outer layer 33 of glass fibre reinforced epoxy resin, a core layer 37 of a syntactic epoxy foam (an epoxy foam with hollow glass particles as filler) and an inner layer 35 also of glass fibre reinforced epoxy resin. Whilst the inner composite panel 34 is formed of three layers: an outer layer 41 of basalt fibre reinforced phenolic resin, a core layer 43 of a syntactic phenolic foam (an phenolic foam with hollow glass particles as filler) and an inner layer 39 also of basalt fibre reinforced phenolic resin.

The outer composite panel formed of epoxy based resin materials has excellent stmctural properties. The inner composite panel formed of phenolic resin based materials has excellent structural and fire resistant properties. Thus, use of panel units in the hull of the boat 1 provides a double-hulled water vessel with both good structural hull properties and excellent fire resistant hull properties.

In the building or structure embodiment, both the inner and outer panels comprise a first layer of a first fibre reinforced resin bonding agent, a core layer of an aggregate or aggregate-cement or aggregate-resin mix preferably about 3-5% w/w ratio to the grit, and a second layer of a second fibre reinforced resin.

Figure 9 shows a perspective view of a boat 101 according to another embodiment of the present invention. Figure 2 shows a starboard side view of the boat 101. The boat 101 is a large motor yacht suitable for use in rivers, estuaries, inshore or offshore.

As shown in Figure 9, the boat 101 has a bow 102, a stem 104 and port side panel 106. The port side panel 106 is one of a number of panel unit each being formed of two composite panels of similar general construction to those in relation to the boat of Figure 1 and as shown in more details in Figures 5 to 7 and acts as a port strake extending substantially the whole length of the port side of the boat 101. In the port side panel(s) 106 are a number of square portholes 106a. The boat 101 is constructed of a number of panel units. The boat 101 has a cockpit 110 with seats, controls and facilities for the crew and passengers and a canopy roof 110a. A lower fender strake 111 extends from the stem 104 to near the bow 102 of the port side. A similar lower fender strake (not shown in Figure 9, see Figure 10) extends along the starboard side. The lower fender strake 111 acts as a space saving walkway along the side of the boat 101. An upper fender strake 113 is also present.

As shown in Figure 10, the boat 1 has a keel 112. The boat 101 may have propellers (not shown) that may be inboard or outboard or inboard or outboard impellers (not shown). The starboard side panel 107 also has a number of square portholes 107a.

Figure 11 is a front view of a vessel as in Figure 9. In addition to the parts illustrated in Figures 9 and 10, boat 101 has port lower hull panel 116 and starboard lower hull panel 118 joined at the keel 112 by a keel strake 114. Also shown is radar reflector 110b.

As shown in the Figures the construction of water vessels according to the invention may encompass both relatively small vessels (e.g. tender boat 1) and larger yachts such as boat 101. The construction using panel unit enables strong light vessel structure and efficient construction.

The core layers of the composite panels used in the boat embodiment as illustrated in the drawings and as used to construct vessels according to the invention may contain syntactic or other solid foam materials. Syntactic foam has the great advantage of lightness but excellent strength and stiffness. Table 1, below shows the components of both the epoxy and phenolic resins syntactic foams. Table 2 shows the physical properties of suitable syntactic foam and solid foam materials that may be used as core layer materials in the composite panels used in embodiments of the invention.

Table 1

Table 2

Reference Numerals

Reference Feature numeral 1 Boat 2 Bow 4 Stern 6 Port side panel 7 Starboard side panel 8 Top deck panel 9 Lower deck panel 10 Cockpit 12 Keel 14 Keel strake 16 Port lower hull panel 18 Starboard lower hull panel 20 Engine 22 Wheel 24 Bulkhead panel 26 Frame 27 Port gunwale stringer 28 Port waterline stringer 30 Port first lower stringer 31 Port second lower stringer 32 Port panel unit outer composite panel 33 Outer composite panel outer layer 34 Port panel unit inner composite panel 35 Outer composite panel inner layer 36 Port panel unit space 37 Outer composite panel core layer 38 Port panel unit upper profile 39 Inner composite panel inner layer 40 Port panel unit lower profile 41 Inner composite panel outer layer 42 Lower deck panel unit upper composite panel 43 Inner composite panel core layer 44 Lower deck panel unit lower composite panel 46 Lower deck panel unit port profile 48 Lower port hull panel unit upper profile 49 Lower port hull panel unit lower profile 50 Port lower hull panel starboard profile 51 Port lower hull panel port profile 52 Starboard side lower hull panel port profile 54 Centre profile 55 Centre bulkhead brackets 56 Centre bulkhead panel 58 Port chine profile 60 Upper deck panel unit port profile 101 Boat 102 Bow 104 Stern 106 Port side panel 106a Porthole 107 Starboard side panel 107 a Porthole 110 Cockpit 110a Canopy roof 110b Radar reflector 111 Lower fender strake 112 Keel 113 Upper fender strake 114 Keel strake 116 Port side hull panel 118 Starboard side hull panel

Claims

Claims.

1. A water vessel comprising at least four panel units, each panel unit having three or more sides, and having at least one joining part on a portion of each side, wherein each joining part is adapted to join the panel unit to a joining part on another panel unit.

2. A water vessel as claimed in claim 1, wherein each panel unit for each of its sides is joined to at least one other panel unit.

3. A water vessel as claimed in either claim 1 or claim 2, comprising at least one port side hull panel unit, at least one starboard side hull panel unit, at least one deck panel unit and at least one lower hull panel unit.

4. A water vessel as claimed in claim 3, comprising at least two lower hull panel units.

5. A water vessel as claimed in claim 4, wherein the at least two lower hull panel units form a chined hull over at least a portion of the length of the water vessel.

6. A water vessel as claimed in any one of the preceding claims wherein the water vessel is a multi-hulled water vessel.

7. A water vessel as claimed in any one of the preceding claims, wherein at least some of the panel units form lateral strakes.

8. A water vessel as claimed in any one of the preceding claims, further comprising at least one bulkhead panel unit.

9. A water vessel as claimed in any one of the preceding claims, further comprising at least one strengthening stringer.

10. A water vessel as claimed in claim 8, wherein at least one of the strengthening stringers is a keel strake.

11. A water vessel as claimed in either claim 8 or claim 9, further comprising at least two longitudinal strengthening stringers.

12. A water vessel as claimed in any one of the preceding claims, further comprising at least one strengthening girder.

13. A water vessel as claimed in any one of the preceding claims, further comprising at least one fender strake

14. A water vessel as claimed in any one of the preceding claims, comprising at least six panel units.

15. A water vessel as claimed in any one of the preceding claims, wherein each panel unit has four or more sides.

16. A water vessel as claimed in any one of the preceding claims, wherein each joining part comprises a mechanical joining part.

17. A water vessel as claimed in claim 16, wherein each mechanical joining part comprises at least one male joining portion, at least one female joining portion or at least one male joining portion and at least one female joining portion.

18. A water vessel as claimed in any one of the preceding claims, wherein a profile extends along a portion of each side of each panel unit and the profile comprises the joining part.

19. A water vessel as claimed in any one of the preceding claims, wherein a, or each, panel unit comprises at least one composite panel.

20. A water vessel as claimed in any one of the preceding claims, wherein the water vessel is double-hulled.

21. A water vessel as claimed in any one of the preceding claims, wherein a, or each, panel unit comprises an outer composite panel and an inner composite panel.

22. A water vessel as claimed in claim 21, wherein the outer composite panel and the inner composite panel are made of different materials.

23. A water vessel as claimed in claim 22, wherein the outer composite panel is designed as a structural panel and the inner panel is designed as a fire resistant panel.

24. A water vessel as claimed in any one of claims 21 to 23, wherein the panel units are arranged such that the outer composite panel and the inner composite panel are connected by at least one profile extending along and fixed to a portion of the inner panel and the outer panel.

25. A water vessel as claimed in any one of claims 18 to 24 wherein one or more profiles are of hollow cross section.

26. A water vessel as claimed in any one of the preceding claims, wherein each joining part is adapted to join the panel unit to a joining part on another panel unit with a joint overlap of a predetermined size or greater, preferably the predetermined size is 140 mm.

27. A water vessel as claimed in any one of claims 19 to 26, wherein the composite panels comprise, a. a first layer of a first fibre reinforced resin, b. a core layer of a solid foam, and c. a second layer of a second fibre reinforced resin.

28. A water vessel as claimed in claim 27, wherein the first and/or the second fibre reinforced resins are independently selected from fibre reinforced thermosetting resins.

29. A water vessel as claimed in claim 28, wherein the thermosetting resins are independently selected from epoxy resins, polyurethane resins, vinyl ester resins, polyester resins and phenolic resins.

30. A water vessel as claimed in any one claims 27 to 29, wherein the first and/or the second fibre reinforced resins independently comprise fibres of glass, carbon, aramid, and/or basalt.

31. A water vessel as claimed in any one of claims 27 to 30, wherein the solid foam comprises a core resin.

32. A water vessel as claimed in any one of claims 27 to 31, wherein the solid foam comprises an open cell foam, a closed cell foam or a syntactic foam.

33. A water vessel as claimed in claim 32, wherein the syntactic foam comprises a core resin containing hollow particles.

34. A water vessel as claimed in claim 33, wherein the hollow particles are hollow glass particles.

35. A water vessel as claimed in any one of claims 27 to 34, wherein the core resin is independently selected from epoxy resins, polyurethane resins, vinyl ester resins, polyester resins or phenolic resins.

36. A water vessel as claimed in any one of claims 21 to 35, wherein the outer panel of the panel unit comprises an outer panel first layer of a first fibre reinforced epoxy resin, an outer panel core layer of a syntactic foam comprising an epoxy resin, and an outer panel second layer of a second fibre reinforced epoxy resin.

37. A water vessel as claimed in claim 36, wherein the fibre of the first fibre reinforced epoxy resin and/or the second fibre reinforced epoxy resin comprises organic or inorganic fibres, preferably glass fibre, more preferably glass fibre.

38. A water vessel as claimed in any one of claims 21 to 37, wherein the inner panel of the panel unit comprises an inner panel first layer of a first fibre reinforced phenolic resin, an inner panel core layer of a syntactic foam comprising a phenolic resin, and an inner panel second layer of a second fibre reinforced phenolic resin.

39. A water vessel as claimed in claim 38, wherein the fibre of the first fibre reinforced phenolic resin and/or the second fibre reinforced phenolic resin comprises an inorganic fibres, preferably basalt, carbon or aramid fibre.

40. A method of manufacturing a water vessel, the method comprising, a. providing a keel strake having at least two joining parts, b. proving at least four panel units, each panel unit having three or more sides, and having at least one profile on a portion of each side, wherein each profile comprises a joining part adapted to join the panel unit to a joining part on another panel unit and/or a joining part on the keel strake, c. laying the keel strake on a surface, d. joining a panel unit to the keel strake to form a port hull panel unit and joining a panel unit to the keel strake to form a starboard hull panel unit, e. joining further panel units to the port hull panel unit and starboard hull panel unit.

41. A method of manufacturing a water vessel, the method comprising, forming a panel unit comprising at least one composite panel by laminating together a. a first layer of a first fibre reinforced resin, b. a core layer of a solid foam, preferably a syntactic foam and c. a second layer of a second fibre reinforced resin.

42. A method as claimed in claim 41, wherein laminating comprises a wet lay-up, a vacuum assisted resin transfer moulding process and/or pultrusion.

43. A water vessel substantially as herein described with reference to the accompanying drawings.